US6365438B1 - Process for manufacturing semiconductor package and circuit board assembly - Google Patents

Process for manufacturing semiconductor package and circuit board assembly Download PDF

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Publication number
US6365438B1
US6365438B1 US09/194,735 US19473598A US6365438B1 US 6365438 B1 US6365438 B1 US 6365438B1 US 19473598 A US19473598 A US 19473598A US 6365438 B1 US6365438 B1 US 6365438B1
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United States
Prior art keywords
manufacturing
semiconductor package
package according
electrodes
circuit board
Prior art date
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Expired - Lifetime
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US09/194,735
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English (en)
Inventor
Yoshihiro Ishida
Kiyoshi Shimizu
Tetsuo Sato
Shinichi Nishikata
Shuichi Ishiwata
Atsushi Omura
Tsutomu Ohara
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Citizen Watch Co Ltd
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Citizen Watch Co Ltd
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Publication date
Priority claimed from JP11922097A external-priority patent/JP4115553B2/ja
Priority claimed from JP15868897A external-priority patent/JP4115556B2/ja
Priority claimed from JP15868997A external-priority patent/JP4115557B2/ja
Priority claimed from JP25650397A external-priority patent/JP4115560B2/ja
Priority claimed from JP29531797A external-priority patent/JP3964515B2/ja
Application filed by Citizen Watch Co Ltd filed Critical Citizen Watch Co Ltd
Assigned to CITIZEN WATCH CO., LTD. reassignment CITIZEN WATCH CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: OMURA, ATSUSHI, ISHIDA, YOSHIHIRO, ISHIWATA, SHUICHI, NISHIKATA, SHINICHI, OHARA, TSUTOMU, SATO, TETSUO, SHIMIZU, KIYOSHI
Publication of US6365438B1 publication Critical patent/US6365438B1/en
Application granted granted Critical
Assigned to CITIZEN HOLDINGS CO., LTD. reassignment CITIZEN HOLDINGS CO., LTD. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: CITIZEN WATCH CO., LTD.
Assigned to CITIZEN WATCH CO., LTD. reassignment CITIZEN WATCH CO., LTD. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: CITIZEN HOLDINGS CO., LTD.
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Definitions

  • the present invention relates to a manufacturing process for a small-sized and thin type semiconductor package. More particularly, to a manufacturing process for a semiconductor package by which an circuit substrate will not be wasted and which allows a plurality of packages to be taken from the substrate thereby having the highly productivity and to an circuit substrate aggregation or assembly used for manufacturing such packages.
  • circuit board aggregation or assembly 100 In manufacturing circuit board aggregation or assembly 100 at a manufacturer's site, a roll of 1 m wide glass filler sheet having a resin impregnated thereinto is cut in accordance with a standard size of 1 m ⁇ 1 m or 1 m ⁇ 1.2 m. Then, a copper film is laminated onto the both sides of the standardized sheet, which will be pressed into an original substrate. The original substrate is further cut into substrate materials with a convenient and readily usable size.
  • FIG. 20 a plan view of substrate material 110 is shown.
  • This substrate material is obtained by cutting an original sheet with a standard size into nine pieces.
  • Substrate material 110 measures 330 mm wide (W) and 330 mm long (L). For example, ten (10) strips of circuit board aggregation 100 will be obtained by cutting this substrate material 110 .
  • Each circuit substrate aggregation is, for example, 56 mm wide (W 1 ) and 115 mm long (L 1 ).
  • Each circuit substrate aggregation 100 is, as illustrated in FIG. 20, arranged as two vertical rows X and five horizontal columns.
  • circuit substrate aggregation 100 has a blank area (margins) for manufacturing packages along the perimeter.
  • the substrate has a b 1 wide (for example 5 mm) manufacturing blank area along the vertical perimeter and b 2 wide (for example 7 mm) manufacturing blank area along the horizontal perimeter.
  • FIGS. 22A to 23 C′ A conventional manufacturing process for CSP type semiconductor packages will now be briefly explained by referring to FIGS. 22A to 23 C′.
  • FIGS. 22A-22C and FIGS. 23A-23C respectively, top plan views are shown in the right side of the figures while cross-sectional views obtained by cutting the top plan views along the cutting lines are shown in the left side.
  • FIGS. 22A to 23 C′ four circuit substrates are illustrated to be taken.
  • a conventional process for manufacturing semiconductor packages includes the steps for forming a circuit substrate (FIG. 22 A′), mounting IC chips onto the substrate (FIG. 22 B′), encapsulating the mounted chips with resin (FIG. 22 C′), attaching standard member on the encapsulated (sealing) chips (FIG. 23 A′), dicing the chips (FIG. 23 B′) and forming electrodes on the chips (FIG. 23 C′).
  • through-holes are formed on the circuit substrate aggregation 100 , both surfaces of which are copper laminated in the step of forming the circuit substrate.
  • this circuit substrate aggregation 100 copper-plated layers are formed by means of electroless copper plating and electro copper plating. Further, the copper-plated layers are laminated with etching resist, which will be sequentially exposed to light and developed to form pattern masks. Thereafter, the copper-plated layers are subjected to pattern etching via the pattern masks by using etching solution. Through this pattern etching process, several sets of IC connecting electrodes (bonding pattern) 3 for a plurality of chips are formed on the upper surface of circuit substrate aggregation 100 and external connection electrodes 4 , which are pad electrodes arranged in a matrix, are formed on the bottom side, respectively.
  • a solder resist processing follows, thereby forming a resist film on the bottom side of circuit substrate aggregation 100 .
  • This resist film has openings where external connection electrodes 4 , which are the solderable region, are exposed.
  • the bottom surface of integrated surface 100 will be planarized.
  • the circuit substrate aggregation is completed wherein a number of same-shaped platable regions are arranged on the bottom surface in a matrix manner (FIGS. 22 A and 22 A′).
  • solder bumps 5 are formed on the pad electrode of the IC wafer (not shown).
  • the process for forming solder bumps 5 includes the stud bump method, ball bump method and plated bump method.
  • the plated bump method among these is suitable for miniaturizing the IC chips because it allows the bumps to be formed in a narrow space between the pad electrodes.
  • the IC wafer on which the solder bumps are formed is cut into chips of a predetermined size while being attached on a adhesive tape, to thereby form the IC chips 6 .
  • the full-cut scheme is employed in cutting the wafer in the X and Y directions with an apparatus such as a dicing saw. After the wafer is cut, IC chips 6 on the adhesive tape are separated into a plurality of individual units.
  • flux (not shown) is applied onto a predetermined location of either the solder bumps of the divided IC chips or IC connecting electrodes 3 formed on the upper surface of circuit substrate aggregation 100 .
  • IC chips 6 are mounted on the main surface of circuit board aggregation 100 in such a manner that one chip is mounted on a single circuit substrate.
  • the surface of IC chip 6 on which solder bumps 5 are formed is opposed against the upper side of the circuit substrate aggregation and solder bumps 5 are positioned on IC connecting electrodes 3 .
  • IC connecting electrodes 3 are electrically connected to IC chips 6 by means of a solder reflow processing.
  • IC chips 6 flip-chips
  • circuit board aggregation 100 FIGGS. 22 B and 22 B′.
  • a plurality of IC chips 6 is integrally encapsulated using a thermosetting resin 7 by performing a side-potting across the adjacent IC chips 6 .
  • the same IC chips 6 are secured on each circuit substrate 1 of the circuit substrate aggregation 100 with the face down direction as shown in FIGS. 22 C and 22 C′.
  • the planar bottom surface of the circuit substrate aggregation on which the IC chips are mounted is attached to standard member 8 by using a adhesive or a PSA (pressure-sensitive adhesive) tape.
  • the adhesion between circuit substrate aggregation 100 and standard member 8 is secured because both of the attached surfaces are planar (FIGS. 23 A and 23 A′).
  • circuit substrate aggregation 100 is cut with a cutting device such as a dicing saw along the cut lines formed on the circuit substrate aggregation in the X and Y directions and the cut circuit substrate 1 is separated into individual circuit substrates 1
  • a dicing machine DFD-640 product name
  • a dicing blade NBC-ZB1090S3 product name both manufactured by Disco Corporation is used in this cutting process.
  • circuit substrates 1 are detached from standard member 8 by dissolving the adhesive and the like with a solution.
  • solder balls are attached to external connection electrodes 4 formed on the bottom surface of the individual circuit substrate. Then, the solder balls are subjected to a reflow process and ball electrodes are formed.
  • the above described process for manufacturing the semiconductor packages suffers from the following problems.
  • the solder ball electrodes are individually formed on a single circuit substrate already diced from the integrated semiconductor substrates.
  • the distance between the perimeter of the circuit substrate and the center of the solder ball electrode positioned most adjacent to the perimeter tends to be small, so that it will be difficult to maintain the blank area reserved to secure an apparatus for attaching the solder balls in the step of forming the solder balls.
  • the productivity of this method is low, so that the manufacturing cost increases.
  • the conventional circuit board aggregation have further problems. As small portable devices are required to be miniaturized, the packages have been strongly requested to be miniaturized and made thinner as well as to lower the manufacturing cost of the packages as much as possible. Since blank areas are reserved for manufacturing purposes, the number of the circuit substrates to be taken therefrom tends to be small. For example, when the blank area b 2 along the horizontally oriented F 1 is 7 mm wide, the total width of the two blank areas for manufacturing purposes along the both sides will be 14 mm, which is equal to more than one row of circuit substrate 1 which is 9 mm ⁇ 9 mm. If all the blank areas are eliminated from circuit substrate aggregation 100 as shown in FIG. 21, as many as sixty circuit substrates, each having an area of 9 mm ⁇ 9 mm, can be taken from the substrate. In reality, however, only 55 circuit substrates 1 may be taken because there exist blank areas. Therefore, about 9% of the circuit substrate will be wasted.
  • an object of the present invention is to provide a circuit board aggregation or assembly, the productivity of which is high and thus which may be preferably used to manufacture semiconductor substrates at a low cost.
  • the process for manufacturing a semiconductor package with mounted IC chips of the present invention comprises,
  • circuit board fabricating step for forming a plurality of bonding patterns for mounting IC chips on a main surface of a circuit board aggregation or assembly which can be divided into a plurality of circuit boards, and forming a plurality of electrode patterns for external connection on the back of this circuit board aggregation,
  • an IC chip mounting step for mounting IC chips on each circuit board of the main surface of the circuit board aggregation and electrically connecting the bonding patterns and IC chips
  • an attaching step for causing the package aggregation unit fabricated by the circuit board fabricating step, IC chip mounting step, sealing step, and electrode forming step to be affixed to a standard member
  • a cutting step which comprises cutting the attached package aggregation unit into each circuit board, thereby obtaining a plurality of semiconductor packages each including one circuit board.
  • the cutting step follows the electrode forming step
  • electrodes having the projections can be formed on all circuit boards of the circuit board aggregation at the same time. This ensures the high productivity and the reduction of the production costs.
  • the margin for the fabrication of the circuit board aggregation can be used as the margin for a solder ball on anchoring a jig in the electrodes having projection forming step.
  • a spacer can be provided on the area from which the circuit board packages are separated such as a margin for fabrication. If the area to be separated is secured to the standard member through this spacer, pieces in the separation area can be prevented from jumping up and down in the dicing machine during the cutting operation. As a result, damage of the dicing blades and IC chips can be prevented.
  • circuit board aggregation of the present invention is provided with the margins for fabrication only along the peripheries of two opposing sides out of four sides of the quadrilateral surrounding the circuit board aggregation. This enables a greater number of circuit boards to be made from the circuit boards aggregation.
  • circuit board aggregation which is suitable for the manufacture of the semiconductor packages inexpensively and with high productivity can be provided by the present invention.
  • the manufacturing process can be automated and productivity of the circuit board aggregation can be further improved by providing the substrate with a width (W) equivalent to a common length (A) which satisfies the following conditions.
  • W a width equivalent to a common length (A) which satisfies the following conditions.
  • FIGS. 1 A- 1 D′ relate to a first embodiment of the invention and show step diagrams to be referred to in describing a process for manufacturing semiconductor packages
  • FIGS. 1 A and 1 A′ show diagrams to be referred to in describing the step of forming the electrodes
  • FIGS. 1 B and 1 B′ show diagrams to be referred to in describing the step of affixation
  • FIGS. 1 C and 1 C′ show diagrams 5 to be referred to in describing the step of dicing
  • FIGS. 1 D and 1 D′ show a completed semiconductor package.
  • FIGS. 1 A′, 1 B′, 1 C′, 1 D′ are plan views shown on the right side
  • FIGS. 1A, 1 B, 1 C, 1 D are cross sectional views cut along the respective cutting lines shown on the left side.
  • FIGS. 2A and 2B relate to the first embodiment of the invention and show diagrams which will be referred to in describing the step of planarization wherein FIG. 2A shows a cross sectional view used to describe the first exemplary step and FIG. 2B shows a cross sectional view used to describe the second exemplary step.
  • FIGS. 3A and 3B relate to the first embodiment of the invention and show diagrams which will be referred to in describing the step of forming planar surfaces wherein FIG. 2A shows a cross sectional view to be referred to in describing the third exemplary step and FIG. 3B shows a cross sectional view to be referred to in describing the fifth exemplary step.
  • FIG. 4 relates to the first embodiment of the invention and shows a plan view of the circuit substrate aggregation which will be referred to in describing the step of dicing.
  • FIGS. 5 A- 5 D′ relate to a second embodiment of the invention wherein FIGS. 5A, 5 A′ show diagrams to be referred to in describing the step of forming electrodes, FIGS. 5B, 5 B′ show diagrams to be referred to in describing the first exemplary step of forming spacers, FIGS. 5C, 5 C′ show diagrams to be referred to in describing the step of affixation and FIGS. 5D, 5 D′ show diagrams to be referred to in describing the step of dicing.
  • FIGS. 6A and 6B relate to the second embodiment of the invention wherein FIG. 6A shows a back surface view of a circuit substrate aggregation on which spacers are formed in accordance with the second exemplary step and FIG. 6B shows a cross sectional view cut along line 6 B— 6 B of FIG. 6 A.
  • FIGS. 7A and 7B relate to the second embodiment of the invention wherein FIG. 7A shows a back surface view of a circuit substrate aggregation on which spacers are formed in accordance with the third exemplary step and FIG. 7B shows the cross sectional view cut along line 7 B— 7 B of FIG. 7 A.
  • FIGS. 8 A- 8 B′ relate to a third embodiment of the invention wherein FIGS. 8A, 8 A′ show diagrams to be referred to in describing the step of affixation and FIGS. 8B, 8 B′ show diagrams to be referred to in describing the step of dicing.
  • FIGS. 8 A′ and 8 B′ are plan views shown on the right side while FIGS. 8A and 8B are cross sectional views cut along the respective cutting lines of the plan views and shown on the left side.
  • FIGS. 9A and 9B relate to the third embodiment of the invention and will be referred to in describing the planarization step wherein FIG. 9A shows a cross sectional view to be referred to in describing the first exemplary step and FIG. 9B shows a cross sectional view to be referred to in describing the second exemplary step.
  • FIGS. 10A and 10B relate to the third embodiment of the invention and will be referred to in describing the planarization step wherein FIG. 10A shows a cross sectional view to be referred to in describing the third exemplary step and FIG. 10B shows a cross sectional view to be referred to in describing the fourth exemplary step.
  • FIG. 11 relates to the third embodiment of the invention and will be referred to in describing the planarization step, showing a cross sectional view to be referred to in describing the fifth exemplary step.
  • FIGS. 12A-12D relate to a fourth embodiment of the invention wherein FIG. 12A shows a diagram to be referred to in describing the step of forming electrodes, FIG. 12B shows a diagram to be referred to in describing the first exemplary step of forming spacers, FIG. 12C shows a diagram to be referred to in describing the step of affixation and FIG. 12D shows a diagram to be referred to in describing the step of dicing.
  • FIGS. 13A and 13B relate to the fourth embodiment of the invention and show cross sectional views of an integrated package body on which spacers are formed.
  • FIGS. 14A and 14B relate to the fourth embodiment of the invention wherein FIG. 14A shows a cross sectional view of an integrated package body on which spacers are formed in accordance with the second exemplary step and FIG. 14B shows a cross sectional view of an integrated package body on which spacers are formed in accordance with the third exemplary step.
  • FIG. 15 A and FIG. 15B relate to a fifth embodiment of the invention wherein FIG. 15A shows a diagram to be referred to in describing the step of affixation and FIG. 15B shows a diagram to be referred to in describing the step of dicing.
  • FIGS. 16A and 16B relate to a sixth embodiment of the invention wherein FIG. 16A shows a diagram to be referred to in describing the step of affixation and FIG. 16B shows a diagram to be referred to in describing the step of dicing.
  • FIG. 17 relates to a seventh embodiment of the invention and shows a plan view of the circuit substrate aggregation.
  • FIGS. 18 A- 18 C′ relate to an eighth embodiment of the invention and will be referred to in describing a process for manufacturing semiconductor packages
  • FIGS. 18A, 18 A′ show diagrams to be referred to in describing the step of forming circuit substrates
  • FIGS. 18B, 18 B′ show diagrams to be referred to in describing the step of mounting IC's
  • FIGS. 18C, 18 C′ show diagrams to be referred to in describing the step of resin encapsulation.
  • FIGS. 18 A′, 18 B′, 18 C′ are plan views shown on the right side
  • FIGS. 18A, 18 B, 18 C are cross sectional views cut along the respective cutting lines and shown on the left side.
  • IC connecting electrodes 3 and externally connecting electrodes 4 are not shown.
  • FIGS. 19 A- 19 D′ are step diagrams following FIGS. 18 C and 18 C′ wherein FIGS. 19A, 19 A′ show diagrams to be referred to in describing the step of forming electrodes, FIGS. 19B, 19 B′ show diagrams to be referred to in describing the step of affixation, FIGS. 19C, 19 C′ show diagrams to be referred to in describing the step of forming spacers and FIGS. 19D, 19 D′ show diagrams to be referred to in describing the step of dicing.
  • FIGS. 19 A′, 19 B′, 19 C′, 19 D′ are plan views shown on the right side while FIGS. 19A, 19 B, 19 C, 19 D are cross sectional views cut along the respective cutting lines of the plan views and shown on the left side.
  • IC connecting electrodes 3 and externally connecting electrodes 4 are not shown.
  • FIG. 20 shows a plan view of a substrate material.
  • FIG. 21 shows a plan view of a conventional circuit substrate aggregation.
  • FIGS. 22A to 22 C′ show step diagrams to be referred to in describing a conventional process for manufacturing semiconductor packages
  • FIGS. 22A, 33 A′ show diagrams to be referred to in describing the step of forming circuit substrates
  • FIGS. 22B, 22 B′ show diagrams to be referred to in describing the step of mounting IC's
  • FIGS. 22C, 22 C′ show diagrams to be referred to in describing the step of resin encapsulation.
  • FIGS. 22 A′, 22 B′, 22 C′ are plan views shown on the right side
  • FIGS. 22A, 22 B, 22 C are cross sectional views cut along the respective cutting lines of the plan views and shown on the left side.
  • IC connecting electrodes 3 and externally connecting electrodes 4 are not shown.
  • FIGS. 23 A- 23 C′ are step diagrams following FIGS. 22C, 22 C′ wherein FIGS. 23A, 23 A′ show diagrams to be referred to in describing the step of forming electrodes, FIGS. 23B, 23 B′ show diagrams to be referred to in describing the step of affixation and FIGS. 23C, 23 C′ show diagrams to be referred to in describing the step of dicing.
  • FIGS. 23 A′, 23 B′, 23 C′ are plan views shown on the right side while FIGS. 23A, 23 B, 23 C are cross sectional views cut along the respective cutting lines and shown on the left side.
  • IC connecting electrodes 3 and externally connecting electrodes 4 are hot shown.
  • the steps of forming circuit substrates, the step of mounting IC's and the step of encapsulating by using resin will be substantially the same as the conventional steps already described by referring to FIGS. 22 A- 22 C′. Accordingly, these steps will not be discussed.
  • the step of forming electrodes will follow the step of resin encapsulation.
  • solder balls are positioned on the externally connecting electrode 4 formed on the back surface of each of circuit substrate 1 and subjected to a reflow processing, thereby forming protruded solder ball electrodes 9 as shown in FIG. 1 A.
  • composition of the solder balls is, as expressed in weight percentage, 40% of Pb and 60% of Sn with the melting point being at 180° C.
  • composition of the solder bumps used to mount IC chips 6 is, as expressed in weight percentage, 90% of Pb and 10% of Sn with the melting point being at 250° C., which is different from that of the solder balls.
  • the attaching step is performed.
  • package body 100 a formed as the result of the steps of forming circuit substrates, mounting IC's and encapsulating by using resin is attached to a standard member.
  • package body 100 a is attached to standard member (for example, dicing tape) 8 with the side on which solder ball electrodes 9 are formed being directed to the standard member.
  • package body 100 a it is preferable for package body 100 a to be secured to standard member 8 by means of a fixing means such as an adhesive (including a PSA (pressure-sensitive adhesive) tape).
  • a fixing means such as an adhesive (including a PSA (pressure-sensitive adhesive) tape).
  • an adhesive including a PSA (pressure-sensitive adhesive) tape.
  • ultraviolet ray reactive type resin may be used as an adhesive agent, which can be, for example, UV tape “UE-2091J” (product name) manufactured by Nitto Denko Corporation. This UV tape may be used as two-side adhesive. Upon being radiated by ultraviolet rays, the adhesion provided by this tape will drastically be decreased so that it will be readily detached. Alternatively, a thermally reactive type resin or a solvent reactive type resin may be used.
  • package body 100 a may be attached to standard member 8 by vacuuming.
  • the surface of package body 100 a on which solder ball electrodes 9 are formed, or the back surface of integrated circuit substrate 100 is not planar because of the formation of the solder ball electrodes 9 .
  • the top of each of solder ball electrodes 9 is planarized to the same height in the planarization process.
  • the top portion of each of solder ball electrodes 9 is cut off so as to achieve the planarized level shown in FIG. 2 A.
  • a predetermined amount of the top portions is polished off by means of a polishing means such as a grinder, so that planarized surface 9 a is formed on each of the top portions.
  • planarized surface 9 a is attached to standard member 8 by means of an adhesive (including adhesive tape) or vacuum method.
  • the top of each of solder ball electrodes 9 is planarized to the same height in the planarization.
  • the top portions of each of solder ball electrodes 9 is heated so as to achieve the planarized level shown in FIG. 2 B.
  • the surface of package body 100 a on which the solder ball electrodes are formed is attached to heating plate 11 . Then, by maintaining this heating plate at a predetermined temperature, a certain amount of the top portions of solder ball electrodes 9 are melted so that planarized surface 9 a is formed.
  • planarized surface 9 a is attached to standard member 8 as in the case of the first exemplary step.
  • solder ball electrodes 9 are buried into resin 13 so that the upper surface of resin 13 forms a planarized surface as shown in FIG. 3 A.
  • frame member 12 is set on the perimeter of the back surface of integrated circuit substrates 100 .
  • This frame member 12 is consisted of metal or plastic member.
  • Resin 13 is then filled into the area surrounded by frame member 12 on the back surface so that solder ball electrodes 9 are buried in resin 13 .
  • thermally reactive type resin is used as resin 13 .
  • planarized surface 13 a is obtained as the cured upper surface of resin 13 .
  • planarized surface 13 a is secured to a standard member by means of adhesive or vacuum attraction.
  • solder ball electrodes 9 are buried in a resin so that the upper surface of the resin will form a planarized surface.
  • solder ball electrodes 9 are buried in the resin by the screen printing method.
  • a metal mask “T-31” (product name) manufactured by Asahi Kaken Corporation is used for the screen printing.
  • the resin is hardened at the temperature of about 130° C.
  • planarized surface is attached to standard member 8 as in the case of the third exemplary step.
  • frame member 12 a is set on main surface 8 a of standard member 8 .
  • the combination of main surface 8 a and frame member 12 a will form a bath.
  • Standard member 8 is mounted on Peltier element 14 .
  • material layer 15 is formed to be surrounded by frame member 12 a on this main surface 8 a , which reversibly changes into a solid state or a liquid state depending upon temperature.
  • the material used for material layer 15 is water in this case.
  • solder ball electrodes 9 At least a portion of solder ball electrodes 9 including the top thereof is immersed into liquid material layer 15 as shown in FIG. 3 B.
  • material layer 15 is changed into a solid state while a portion of solder ball electrodes 9 is immersed therein. Water is frozen into ice by using Peltier element to cool down the material layer to a temperature below the freezing point. As the result, package body 100 a is fixed to standard member 8 with water as an adhesive.
  • the material for the material layer is not limited to water.
  • a wax such as commercially available “apieson” may also be used. Wax, which is in a solid state at a room temperature, becomes liquid by heating it to a higher temperature.
  • the cutting step is now performed on the package body attached to standard member 8 by either of the first to fifth exemplary steps described above.
  • package body 100 a is diced into circuit substrates 1 as shown in FIG. 1 C and 1 C′.
  • standard member 8 to which package body 100 a is attached is set to a dicing apparatus (not shown).
  • a dicing apparatus “DFD-640” (product name) manufactured by Disco Corporation is used for example.
  • NBC-ZB109OS3 product name
  • This dicing blade is rotated 3000 rotations per minute and moved 50 mm per second with respect to the standard member. Pure water is supplied to the dicing interface at the rate of 1.5 liter per minute, so that it will cool down the interface and remove the particles.
  • solder ball electrodes 9 When solder ball electrodes 9 are immersed into a resin in the affixation step, the resin is also diced together with said package body. After the cutting step, completed semiconductor package 100 a is detached from standard member 8 . Then, diced package body 100 a is separated into individual substrates 1
  • circuit substrate 1 is detached from standard member 8 , thereby obtaining completed semiconductor package 10 as shown in FIG. 1 D and 1 D′.
  • solder ball electrodes 9 are attached to standard member 8 by means of an adhesive
  • the completed semiconductor package is washed with a washing agent after the exfoliation so as to remove the remaining adhesive.
  • a washing agent “Clean Through” (product name) manufactured by Kao Corporation is used for example. After the cleaning by the washing agent, the package will be further washed with pure water. Then, the completed semiconductor package is dried in an oven.
  • FIG. 4 is a plan view of the integrated circuit substrate.
  • a circuit pattern is formed for the CSP's of a plurality of circuit substrates by the electro-plating method.
  • This circuit pattern comprises common electrodes 16 and 16 a , branched wiring 16 b and circuit pattern 16 c for CSP's .
  • Two common electrodes 16 extend along the X direction.
  • common electrodes 16 a extend in the Y direction by connecting the two common electrodes 16 .
  • Circuit patterns 16 c are arranged to extend from both sides of each common electrode 16 a .
  • Common electrode 16 a and circuit pattern 16 c are connected via a branched wiring 16 b.
  • package body 100 a is formed by using this integrated circuit substrate 100 , this body is diced along the dicing lines indicated by dotted lines A to K and (1) to (5).
  • the distance between the dicing lines in the portions including common electrodes 16 a in the Y direction is smaller than that in other portions (A and B, C and D, F and G, H and I, and J and K).
  • the affixation to the standard member is weaker than in other cases because the area is smaller.
  • the substrate including common electrodes 16 a in the Y direction may be deformed or the dicing line may deviate from the intended dicing lines.
  • the dicing when the dicing is performed along the dicing lines extending in the Y direction, the dicing is performed in the order of A, B, D, E, G, H, I, K, C, F and J. If the dicing is performed in this order, since the dicing lines, the distance between which is small, will not be continuously diced, deformations of the substrates and deviations from the dicing lines will not occur.
  • the dicing is performed along the dicing lines along the X direction, the dicing is performed in the order of (1) to (5).
  • the separation areas other than circuit substrates 1 in integrated circuit substrate 100 for example manufacturing blank areas (margin for fabricating) are cut into separate pieces. In the separation areas, however, no solder balls 9 are formed. Thus, these separation areas may not be attached to standard member 8 in some cases. In such cases, the separated pieces of the separation areas will move about in the dicing machines, which may damage the dicing blades or IC chips.
  • spacers are formed in the separation areas on the back surface of integrated circuit substrate 100 and the separation areas are attached to standard member 8 through these spacers.
  • the step of forming electrodes is performed after the step of resin encapsulation.
  • solder ball electrodes 9 are formed as protruded electrodes as shown in FIG. 5 A.
  • the step of forming spacers is performed before the step of affixation.
  • spacers 17 are formed, as shown in FIG. 5B, on the separation areas of the back surface of integrated circuit substrate 100 which are cut off from circuit substrate 1
  • spacers 17 are formed for the following first to third exemplary steps on all the individual pieces of manufacturing blank areas 1 a.
  • the height of spacers 17 is set as being substantially the same as solder ball electrodes 9 . This is because it is impossible for the separation areas to be fixed to the standard members if the spacers are too low.
  • spacers 17 are formed on each of the defective circuit substrate areas.
  • the material used for spacers 17 will be the same as that of solder ball electrodes 9 .
  • solder balls (not shown) will be placed on the blank area and subjected to a reflow processing, so that the spacers will be formed.
  • spacers 17 are formed together with solder ball electrodes 9 during the step of forming the electrodes.
  • spacers are formed by hardening the resin.
  • Spacers 17 are, as shown in FIG. 6B, placed in a two-dimensional linear pattern for surrounding the area that will be circuit substrate 1 on the manufacturing blank area 1 a of the back surface of integrated circuit substrate 100 .
  • spacers 17 are, as shown in FIG. 7B, placed in a two-dimensional linear pattern for surrounding the area that will be cut as circuit substrate 1 on the manufacturing blank area 1 a of the back surface of integrated circuit substrate 100 .
  • an affixation step is, as in the case of the first embodiment, performed to package body 100 a on which spacers 17 have been formed in accordance with one of the first to third steps described above.
  • a separation area is affixed to standard member 8 via spacers 17 .
  • a cutting step is, as in the case of the first embodiment, performed.
  • the separation area is fixed to standard member 8 .
  • the steps up to the step of forming the electrodes are the same as in the case of the first embodiment.
  • the step of forming the electrodes will not be explained in this embodiment.
  • an affixation step is performed after the step of forming the electrodes.
  • package body 100 a which is formed as the result of the steps of forming the substrate, mounting IC's, encapsulating with resin and forming electrodes is affixed to the standard member.
  • the side of package body 100 a on which IC chips 6 are formed is affixed to the standard member.
  • package body 100 a is affixed to the standard member by using such a fixation means as an adhesive agent (including an adhesive tape), which is the same as in the case of the first embodiment.
  • an adhesive agent including an adhesive tape
  • the side of the package body 100 a on which the IC chips are mounted or the main surface of integrated circuit substrate 100 is not planar.
  • the thickness of the encapsulating resin on the upper side of each IC chip is not the same.
  • the main surface of this integrated circuit substrate 100 it is preferable for the main surface of this integrated circuit substrate 100 to be better planarized so as to be better affixed to standard member 8 .
  • the back surface of integrated circuit substrate 100 will be planarized in accordance with the following first to fifth exemplary steps, which will be described below.
  • the upper surface of each of IC chips 6 is planarized to the same height during the planarization step.
  • the upper surface of each of IC chips is, as shown in FIG. 9A, polished together with encapsulating resin 7 so that the upper surface will be planarized.
  • the height from the main surface of integrated circuit substrate 100 to the planarized upper surface 6 a must be higher than that from this main surface to the circuit surface of the IC's within IC chips 6 .
  • the planarized upper surface is affixed to standard member 8 by means of an adhesive agent (including an adhesive tape) or such fixation means as a vacuum attraction device.
  • the upper surface of each of IC chips 6 is planarized to the same height during the planarization step.
  • the upper surface of the deposited encapsulating resin 7 is polished so that the upper surface will be planarized.
  • the height h 1 from the main surface of integrated circuit substrate 100 to the planarized upper surface 7 a must be higher than that from this main surface to the highest point of the wire bonding.
  • the planarized upper surface is affixed to standard member 8 as in the case of the first exemplary step.
  • planar surface 13 a is formed as the upper surface 13 a of resin 13 as shown in FIG. 10A by burying IC chip 6 by using resin 13 .
  • frame member 12 is set in the outer perimeter of the main surface of integrated circuit substrate 100 .
  • This frame member 12 is composed of a metal or a plastic member.
  • resin 13 is filled into the region surrounded by frame member 12 on the main surface so that the IC chips are buried.
  • thermally reactive resin is used.
  • planar surface 13 a is formed as the hardened upper surface of resin 13 .
  • planar surface 13 a is affixed to the standard member by means of an adhesive agent or such fixation means as a vacuum attraction device.
  • planar surface 13 a is formed as the upper surface of resin 13 by burying IC chips 6 by using resin.
  • IC chips 6 are buried in the resin in accordance with the transmold method.
  • the screen-print method may also be employed.
  • the planar surface is affixed to standard member 8 as in the case of the third exemplary step.
  • the first main surface of a planar board is affixed to the upper surface of the deposited encapsulating resin on the IC chips.
  • the planar board used in this case is a metal board having a good thermal conductivity such as an aluminum board, copper board or an alloy comprising copper and tungsten. This planar board also functions as a heat releaser.
  • the separation area such as a manufacturing blank area other than circuit substrate 1 of integrated circuit substrate 100 is also cut off as individual pieces.
  • the separation areas do not have solder ball electrodes 9 .
  • the separation area may not be affixed to standard member 8 during the dicing process. In such cases, the pieces cut off by the dicing step jump around in the dicing apparatus. Consequently, the dicing blade and IC chips may be damaged.
  • spacers are formed in the separation area on the main surface of integrated circuit substrate 100 and the separation area will be affixed to standard member 8 via these spacers.
  • the step of forming the electrodes follows the step of resin encapsulation.
  • the solder ball electrodes are formed as protruding electrodes.
  • the step of forming the spacers is performed before the step of affixation.
  • spacers 17 are formed on the separation area which will be cut off from circuit substrate 1 in the dicing step on the main surface of integrated circuit substrate 100 as shown in FIG. 12 B.
  • spacers 17 of the following first to third exemplary steps are formed on all the pieces of the manufacturing blank areas 1 a and each of the defective circuit substrate area 1 b where said protruding electrodes are not formed.
  • spacers 17 must be the same as the distance between the integrated circuit substrate 100 and standard member 8 when package body 100 a is affixed to standard member 8 . This is because it is not possible for the separation area to be fixed to the standard member if the spacers are too low.
  • spacers 17 are formed by hardening the resin.
  • an appropriate amount of resin is dropped onto manufacturing blank area 1 a and defective circuit substrate area 1 b .
  • the amount of resin to be dropped must be such that the height of the hardened resin is at least the same height as the distance between integrated circuit substrate 100 and standard member 8 .
  • the upper surface of the resin is pressed down by, for example, a planar board so that the predetermined height of spacers 17 can be obtained.
  • Resins such as thermally hardening resin, ultraviolet hardening resin or thermally deformable resin will be used. If a thermally hardening resin is used, the resin is heated to be hardened after the resin is dropped.
  • base 17 b having adhesive agent 17 a is, as shown in FIG. 14A, used as spacers.
  • base 17 b a board made of a resin or metal will be used.
  • adhesive agent 17 a is attached to at least a portion of the both sides or only one side of base 17 b .
  • Base 17 b is attached to the main surface of integrated circuit substrate 100 using this adhesive agent 17 a.
  • dummy IC chips 17 are formed as spacers 17 .
  • adhesion is not sufficient between dummy IC chips 17 as the spacers and integrated circuit substrates 100 , it is preferable to provide encapsulating resin 7 therebetween.
  • an affixation step is performed, as in the case of the first embodiment, to package body 100 a on which spacers 17 are formed in accordance with the above described first to third exemplary steps.
  • the separation area is affixed to standard member 8 via spacers 17 .
  • a cutting step is performed as in the case of the first embodiment.
  • the separation area is fixed to standard member 8 .
  • the side of package body 100 a on which the solder ball electrodes 9 are formed as in the case of the first embodiment is vacuum attracted to standard member 8 , which will be described below.
  • spacers 17 are formed on manufacturing blank area 1 a of the back surface of integrated circuit member 100 and on the defective circuit substrate area 1 b .
  • an attraction member will be used which has an attracting tube inside.
  • dicing tape 20 is affixed on the upper edge of each of solder ball electrodes 9 .
  • the height of spacers 17 must be the sum of the height of solder ball electrodes 9 and the thickness of dicing tape 20 . For example, if solder ball electrodes 9 are approximately 0.6 mm high and dicing tape 20 is approximately 0.1 mm thick, then spacers 17 are approximately 0.7 mm.
  • This dicing tape 20 and spacers 17 are vacuum attracted to standard member 8 .
  • This standard member 8 has, as shown in FIG. 15A, attracting tube 18 which has attracting openings 18 a for the main surface. One end of the attracting tube is connected to a vacuum pump (not shown).
  • integrated circuit substrate 100 is, as shown in FIG. 15B, cut by a dicing process.
  • the side of package body 100 a formed as in the case in the first embodiment on which IC chips 6 are mounted is vacuum attracted to standard member 8 , which will be explained below.
  • spacers 17 are formed on manufacturing blank area 1 a of the main surface of integrated circuit member 100 and on the defective circuit substrate area 1 b .
  • an attraction member will be used which has an attracting tube inside.
  • dicing tape 20 is affixed on the upper edge of each of solder ball electrodes 9 .
  • the height of spacers 17 must be the sum of the height of IC chips 6 the thickness of IC connecting electrodes 3 and the thickness of dicing tape 20 .
  • IC chips 6 are approximately 0.625 mm high
  • IC connecting electrodes 3 are approximately 0.1 mm thick
  • dicing tape 20 is approximately 0.1 mm thick
  • spacers 17 are approximately 0.825 mm.
  • This dicing tape 20 and spacers 17 are vacuum attracted to standard member 8 .
  • This standard member 8 has, as shown in FIG. 16A, attracting tube 18 which has attracting opening 18 a for the main surface. One end of the attracting tube is connected to a vacuum pump (not shown).
  • integrated circuit substrate 100 is, as shown in FIG. 16B, cut by a dicing process.
  • Integrated circuit substrate 100 in the seventh embodiment is divided into a plurality of circuit substrates 1 .
  • This integrated circuit substrate 100 has, as shown in FIG. 17, manufacturing blank areas 1 a on the opposed two sides F 2 and F 4 of four peripheral sides surrounding itself.
  • the remaining two sides F 1 and F 3 of this integrated circuit substrate do not have manufacturing blank areas. In other words, these two remaining sides are the sides of circuit substrate 1 .
  • Integrated circuit substrate 100 is normally formed from a substrate material by die-cut molding.
  • the edges of a conventional integrated circuit substrate are shear planes die-cut with a mold. Since the shear plane has a coarse surface, it is not preferable as an edge of the circuit substrate.
  • the same cutting method as used to divide integrated circuit substrate 100 into a plurality of circuit substrates 1 is used.
  • the dicing method is, for example, is preferable. If the dicing method is employed, these two sides F 1 and F 3 may be used as the edges of circuit substrate 1 .
  • the edges will be accurately positioned as well as they have a smooth surface.
  • the blank area required for dicing is extremely narrow compared to that for other cutting method.
  • the integrated circuit substrate is formed by cutting the substrate material.
  • This substrate material is formed by cutting an original board with a predetermined size.
  • the original board is normally 1 m wide.
  • Substrate materials are formed by equally dividing this width of 1 m. If 1 m width is equally divided into 2, 3, 4 and 5 parts, the obtained width will be approximately 500, 330, 250 and 200 mm. If the manufacturing blank areas on the both sides are subtracted from these divided widths, the remaining effective value of the divided width will be approximately 490, 320, 240 and 190 mm.
  • the width of the substrate material depends on the number of the dividing of an original board in a predetermined size. Thus, since the area of the unused region, the width of which is smaller than that of integrated circuit substrate, is large in some cases, a quite large amount of material has been wasted in the prior art.
  • the common length (A) of the two sides F 1 and F 3 of all the four sides of integrated circuit substrate 100 is shared by different dividing number (such as K 1 , K 2 ).
  • This is preferably 76 mm to 81 mm wide depending upon the relationship between the number of integrated circuit substrates 100 taken from the substrate material and the width of the integrated circuit material.
  • the manufacturing processes may be readily automated, thereby improving the productivity of the integrated circuit substrate. Consequently, since the manufacturing cost of the integrated circuit substrate can be lowered, the manufacturing cost of the semiconductor packaged may also be lowered.
  • this shared common length is longer than the width of the conventional normal integrated circuit substrate (56 mm).
  • the dividing number by which the substrate material is divided into the integrated circuit substrates may hopefully be fewer than in the conventional cases. If this dividing number may be smaller, the blank area for the division will also be smaller. Therefore, by employing the shared common length, the substrate material can be more efficiently used.
  • Table 1 below shows the widths of the integrated circuit substrates when the dicing method is used.
  • the cutting blank area in this case is 0.2 mm.
  • b represents the divided length of the substrate material and n represents how many the divided length is further divided into.
  • W2 is 79.9 mm if n is four.
  • W2 is 79.9 mm if n is three.
  • Table 2 below shows the widths of the integrated circuit substrates when the routing method is used as the cutting method.
  • the cutting blank area in this routing is 2 mm.
  • b represents the divided length of the substrate material and n represents how many the divided length is further divided into.
  • W2 is 78.5 mm if n is four.
  • W2 is 78.7 mm if n is three.
  • Table 3 shows the widths of the integrated circuit substrates when the routing method is used as the cutting method and cutting is performed so that the cutting blank area is 5 mm wide and a tie bar is left.
  • the cutting blank area in this routing is 0.2 mm.
  • b represents the divided length of the substrate material and n represents how many the divided length is further divided into.
  • the width W2 of the integrated circuit substrate in the case where six is taken is 77.5 mm.
  • W2 is 76.3 mm if n is four.
  • W 2 is 76.7 mm if n is three.
  • integrated circuit substrate 100 may be cut off so that it will have a common width with respect to a plurality of the divided numbers of the original board.
  • integrated circuit substrate 100 is divided into four circuit substrates 1 , which is merely exemplary.
  • This integrated circuit substrate 100 has manufacturing blank areas only on two sides out of four sides on its perimeter, each of which is 5 mm wide.
  • IC connecting electrodes 3 are formed on the main surface of integrated circuit substrate 100 which will be cut into a plurality of circuit substrates 1 and externally connecting electrodes 4 will be formed on the back surface of this integrated circuit substrate 100 . In both cases, these electrodes are arranged for more than one circuit substrate.
  • IC chip 6 is mounted on each of circuit substrate 1 on the main surface of integrated circuit substrate 100 . Further, IC chips 6 are mounted on integrated circuit substrate 100 by electrically connecting IC connecting electrodes 3 and IC chips 6 .
  • solder ball electrodes 9 are formed on externally connecting electrodes 9 .
  • spacers 17 are formed on the manufacturing blank areas 1 a of the main surface of integrated circuit substrate 100 .
  • spacers 17 are formed as linearly extending on two manufacturing blank areas 1 a .
  • the shape of the cross-section of spacers 17 is rectangular.
  • a frame of the manufacturing blank areas are formed on all the four side of the perimeter.
  • the two-dimensional pattern of the spacers will also be of rectangular frame.
  • a layer that will become spacers will first be formed across the integrated circuit substrate and then the area corresponding to circuit substrate 1 will be removed.
  • spacers 17 are formed as a simple linear form, the above removal procedure is not necessary.
  • spacers 17 are more readily formed than in the conventional cases. Since the above removal procedure is not necessary, the material for spacers 17 is scarcely wasted. Thus, the manufacturing cost can be lowered. Since the removal procedure is not necessary, the present method is suitable for automation of the manufacturing process, thereby improving the productivity.
  • package body 100 a which is formed by the steps of forming the circuit substrates, mounting the IC chips, encapsulating with resin and forming the electrodes is affixed to standard member 8 .
  • the side of package body 100 a on which IC chips 6 are formed is affixed to standard member 8 .
  • Manufacturing blank areas 1 a of integrated circuit substrate 100 will be affixed to standard member 8 via spacers 17 .
  • package body 100 is diced, as shown in FIGS. 19 D and 19 D′ into circuit substrates 1 , thereby forming a plurality of completed semiconductor packages each of which surrounds a circuit substrate.
  • the step of forming the electrodes follows the step of resin encapsulation in the above described embodiments, the step of forming the electrodes may be performed at any arbitrary moment if it is after the step of forming the substrate and before the affixation step.
  • the step of forming the electrodes may be performed before the step of mounting the IC chips.
  • the method of manufacturing the semiconductor packages in accordance with the present invention is a suitable method for such semiconductor packages with high reliability and productivity that will be mounted in camera integrated VTR's or small portable devices.
  • integrated circuit substrate of the present invention is suitable for such semiconductor packages with high reliability and productivity that will be mounted in camera integrated VTR's or small portable devices.

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Computer Hardware Design (AREA)
  • Power Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • General Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Dicing (AREA)
  • Encapsulation Of And Coatings For Semiconductor Or Solid State Devices (AREA)
  • Structures Or Materials For Encapsulating Or Coating Semiconductor Devices Or Solid State Devices (AREA)
US09/194,735 1997-05-09 1998-04-24 Process for manufacturing semiconductor package and circuit board assembly Expired - Lifetime US6365438B1 (en)

Applications Claiming Priority (11)

Application Number Priority Date Filing Date Title
JP11922097A JP4115553B2 (ja) 1997-05-09 1997-05-09 半導体パッケージの製造方法
JP9-119220 1997-05-09
JP15868997A JP4115557B2 (ja) 1997-06-16 1997-06-16 半導体パッケージの製造方法
JP9-158689 1997-06-16
JP9-158688 1997-06-16
JP15868897A JP4115556B2 (ja) 1997-06-16 1997-06-16 半導体パッケージの製造方法
JP9-256503 1997-09-22
JP25650397A JP4115560B2 (ja) 1997-09-22 1997-09-22 半導体パッケージの製造方法
JP9-259317 1997-10-28
JP29531797A JP3964515B2 (ja) 1997-10-28 1997-10-28 半導体装置の切断分離方法
PCT/JP1998/001905 WO1998052220A1 (fr) 1997-05-09 1998-04-24 Procede de production d'un boitier pour semi-conducteur et systeme de carte de circuits

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KR (1) KR100568571B1 (de)
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RU2507679C2 (ru) * 2012-04-16 2014-02-20 Виталий Яковлевич Подвигалкин Объемный микроблок вакуумных интегральных схем логических свч-систем обратной волны
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WO1998052220A1 (fr) 1998-11-19
MY123937A (en) 2006-06-30
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KR20000023622A (ko) 2000-04-25
TW395033B (en) 2000-06-21
EP0932198B1 (de) 2015-12-09
CN1225750A (zh) 1999-08-11
KR100568571B1 (ko) 2006-04-07
EP2015359B1 (de) 2015-12-23
EP0932198A1 (de) 1999-07-28
CN1185702C (zh) 2005-01-19

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